| Abstract Scope |
Additive manufacturing (AM) has enabled a paradigm shift, allowing on-demand production and high-mix part fabrication from a single machine. However, aluminum alloys have historically been limited in both composition and build volume—until the recent emergence of additive friction stir deposition (AFSD).
Power consumption, material usage, and build rate—alongside part performance—are critical factors in evaluating the return on investment (ROI) of this technology.
This work evaluates AFSD power usage through precise instrumentation of a MELD L3 machine, measuring current and voltage across all three legs of the 480V primary input, as well as individual legs of all major components. The effects of parametric inputs and various heat treatments on power consumption, deposition rate, and tensile strength were assessed using a design of experiments (DOE) approach.
DOE results were used to baseline AFSD production rates, costs, and energy usage against conventional forging. Overall, AFSD offers significant energy savings, increased flexibility, and a substantially reduced lead time compared to traditional forging methods. |